MULTl-LAYER HEAT SPREADER ASSEMBLY WITH ISOLATED CONVECTIVE FINS

ABSTRACT

An assembly of two or more heatspreaders is attached to a printed circuit board in a compact electronic enclosure. The heatspreaders include fins which assist in convecting heat out of the enclosure through vents. The printed circuit board is shielded from the outer case by the heatspreaders.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of allowed U.S. application Ser. No.14/912,158 filed Feb. 15, 2016, which claims the benefit of PCTApplication PCT/US14/49110 filed Jul. 31, 2014, which claims benefit ofU.S. Provisional Application Ser. No. 61/866,776, filed Aug. 16, 2013,U.S. Provisional Application Ser. No. 61/993,601, filed May 15, 2014,which are incorporated by reference herein in their entirety.

FIELD OF THE INVENTION

The present principles relate generally to electronic devices and, moreparticularly, to a heat sink attachment apparatus and method for anelectronic device.

BACKGROUND OF THE INVENTION

Managing heat in compact electronic enclosures is difficult because theaesthetic and performance demands from customers cause the enclosures tobe form fit to the electronic components with little room for naturalconvection to dissipate heat. Usually, the integrated circuits (ICs)generating the largest amount of heat are located in the center of theenclosure and many customers object to vent openings in the enclosuredirectly above the printed circuit board (PCB). This causes the heat tobe trapped in the enclosure and can damage sensitive components. Also,the outer surfaces of the enclosure can exceed temperature limitsacceptable for a customer's touch.

Numerous approaches for managing heat exist. Some involve employing aplurality of vent openings and providing sufficient space in enclosuresconducive to exhaust heat. However, many customers object to largeenclosure sizes and excessive openings. Heatspreaders are commonly usedin compact electronic enclosures to radiate heat into the walls of theenclosure but their dissipation of heat is limited. Finned heatsinkshave been used in larger enclosures that allow movement of air throughvents. In systems with finned heatsinks, there has to be enough room forair to circulate, and as such, this requirement generally causes theneed for larger enclosures. Fans and blowers are used widely, but theygenerate noise that is objectionable to many customers. Fluid filledheat pipes have been used to transfer heat from the center ofenclosures, but such an approach is expensive.

In most typical set top boxes, the PCB assemblies have components andconnectors mounted on one side of the PCB in which there is an aestheticmotivation to form fit the enclosures to the components. This usuallyplaces one side of the enclosure close to the PCB and the otherrelatively farther away. This makes it useful to be able to draw heat insome directions through conduction and to shield radiation from theenclosure in others; however, this causes the need for the set top boxto have additional height.

It is thus recognized that a further need exists to implement set topbox designs which efficiently eliminate heat and which are compact,quiet, and cost effective.

SUMMARY OF THE INVENTION

An electronic device 10 is provided that comprises a printed circuitboard 4; a first heatspreader 1 having a first plate portion 30 andfirst fins 8T along two sides of the first plate portion, the firstplate portion being above the printed circuit board; and a secondheatspreader 3 having a second plate portion 31 and second fins 8B alongtwo sides of the second plate portion, the second plate portion beingbelow the printed circuit board. The electronic device can include asmart card assembly 5 in which one of the heatspreaders has a cutoutportion in the corresponding plate portion and the smart card assemblyis positioned in the cutout portion. The electronic device can furtherinclude a third heatspreader la having a third plate portion that hasadditional fins 8TT along one side of the third plate portion in whichthe third plate portion is positioned in the cutout portion. Theelectronic device can further include exterior sides 16 and at least oneof the exterior sides can have at least one vent 15 positioned adjacentto at least one of the fins.

Additionally, an electronic device 10 is provided that comprises aprinted circuit board 4; a first heatspreader 1 having a first plateportion 30 and first fins 8T along two sides of the first plate portion,the first plate portion 30 being above the printed circuit board; asecond heatspreader 3 having a second plate portion 31 and second fins8B along two sides of the second plate portion, the second plate portionbeing below the printed circuit board; and a third heatspreader 1 ahaving a third plate portion that is positioned in a cutout portion inthe first plate portion. The electronic device can further includeadditional fins 8TT along one side of the third plate portion.

In the embodiments of the invention, the first fins and/or second finscan be oriented vertically and be parallel to each other. With such anorientation, a plurality of the first and second fins can alternate withone another along both sides of the first and second plate portions.

In the embodiments, the electronic device can have a plurality of thevertical exterior sides 16 having at least one vent 15 positionedadjacent to the fins, wherein the vents are oriented perpendicularly tothe fins. These embodiments can include a top 29 and bottom 2 of theelectronic device in which two opposing exterior vertical sides and edgeportions of the top and bottom adjacent the opposing exterior verticalsides have a plurality of vents 15 positioned adjacent to the fins suchthat the vents are oriented perpendicularly to the fins. Additionally,the bottom 2 can have second vents 17 between the first vents in whichthe first vents 15 can be elongated and can be perpendicular to the finsand the second vents can be elongated and can be parallel to the fins.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be explained in greater detail with reference toembodiments, referring to the appended drawings, in which:

FIG. 1 is an interior top front perspective view of the set top box 10according to the invention;

FIG. 2 is an interior bottom front perspective view of the set top box10 according to the invention;

FIG. 3 is an interior top plan view of the set top box 10 according tothe invention;

FIG. 4 is an interior bottom plan view of the set top box 10 accordingto the invention;

FIG. 5A is an interior top plan view and FIG. 5B is an interiorsectional view according to the invention;

FIG. 6 is an interior top front perspective view of the set top box 10according to the invention;

FIG. 7 is an interior bottom front perspective view of the set top box10 according to the invention;

FIG. 8 is an interior solid bottom plan view without the bottom or baseframe 2 of the set top box;

FIG. 9 is a front perspective view of the set top box according to theinvention; and

FIG. 10 is a bottom plan view of the set top box according to theinvention;

DETAILED DESCRIPTION OF THE INVENTION

The embodiments generally include an assembly of two or more heatspreaders attached to a PCB in a compact electronic enclosure in whichit is preferable to select materials for the heatspreader that havehigher conductivities such as aluminum.

As needed, for particular components to which the heatspreaders areattached, thermally conductive elastic pads can be employed.

The invention will now be described in greater detail whereinembodiments of the present invention are illustrated in the accompanyingdrawings. It should be noted that the expression heatspreader andheatsink are used interchangeably throughout the specification and thatthe embodiments of the invention can employ heatspeaders and/orheatsinks. Heatspreaders are understood to be a structure that extractsheat from hot components by thermal conduction and then permits the heatto be released and/or spread by convention and radiation in a diffusemanner. Heatsinks are understood to be a structure having sufficientmass that also extracts heat from hot components by thermal conductionsuch that the heatsinks effectively absorb heat from hot components.

FIG. 1 is a top front perspective view with some see-through features ofthe electronic device 10 such as a set top box or the like according tothe invention. The top, front side, left side and right side are removedto more clearly show the interior features. The electronic device 10includes a printed circuit board 4; a first heatspreader 1 having afirst plate portion 30 and first fins 8T along two sides or edges of thefirst plate portion in which the first plate portion 30 is above theprinted circuit board; a second heatspreader 3 having a second plateportion 31 and second fins 8B along two sides or edges of the secondplate portion in which the second plate portion is below the printedcircuit board. In this embodiment and others, screws can be driventhrough embosses in the heatspreaders and holes in the PCB. The screwthreads can be driven into the heatspreader embosses or into plasticbosses in the enclosure. At particular locations, one heatspreader only,or combinations of other heatspreaders can be attached to the PCB,depending on the needed conduction of heat.

FIG. 2 is a bottom front perspective view with some see-through featuresof the set top box 10 or the like according to the invention. Thebottom, top, front side, left side and right side are removed to moreclearly show the interior features. In this view, a major heatgenerating component, the smart card/smart card assembly 5, is shown.Here, one of the heatspreaders 3 has a cutout portion in thecorresponding plate portion 31 and the smart card assembly 5 ispositioned in the cutout portion.

FIG. 3 is a top interior plan view of the device 10 showing how the topheatsink 1 and fins 8T are connected. This view further shows the fins8B which are connected to the bottom heatsink 3 and shows how the fins8B can be between the fins 8T. The electronic device can include a paneljack 7 with connectors on the rear wall 6. The top heatsink 1 caninclude a cutout portion as well to accommodate components such as smartcard assemblies.

FIG. 4 is a bottom interior plan view showing how the bottom heatsink 3and fins 8B connect.

FIG. 5A shows a top interior plan view and FIG. 5B shows an interiorsectional view of the set top box. These views show that the topheatsink 1 can be segmented in a manner in which heat from a major heatgenerating component such as a smart card assembly 5 can be at leastpartially extracted separately from heat generated by other components.The smart card assembly region can have a minor top heatsink la asshown, in which the expression “minor” implies a smaller heatsink thanthe top heatsink or implies a heatsink that is dedicated to a specificinternal component. These views shows the central depression 9 of thetop heatsink 1 that contacts the PCB 4 or a thermal contact pad 19thereon to extract heat from the PCB. Likewise these views show adepression 9 a for the minor top heatsink la that extends down from theminor planar portion 32 of the minor top heatsink 1 a. The depression 9a contacts the smart card assembly 5 or the like to transfer heat to theminor top heatsink planar peripheral portion 32 which surrounds thedepression 9 a or part of the depression. The depression 9 a workssimilarly to the depression 9 in how it transfers heat to the planarperipheral portions (first plate portion 30) surrounding depression 9.FIG. 5B also shows feet 11 on the set top box which allows for heat tobe removed from the bottom of the set top box. The feet also allow forair circulation through convention to occur. These views show how screwsin screw depressions 12 can hold the top heatsink 1 to the PCB 4 orbottom 2 and how central depressions can contact the PCB 4. Somedimensions for one of the preferred embodiments of the invention are:

the gap between the bottom 2 and the bottom heatsink 3 equal to 3 mm;

the thickness of the bottom heatsink 3 equal to 2 mm;

the dimension of the top to bottom of the electronic device equal to 38mm;

the circuit board dimension equal to 215 mm×150 mm; and

the gap between the bottom heatsink 3 to circuit board equal to 6 mm.

FIG. 6 is a top front perspective view of the set top box 10 or the likeaccording to the invention. Here, fins 8B are connected to bottomheatsink 3 and fins 8T are connected to the top heatsink 1. On one side,heat is effectively extracted by having the 8B and 8T fins alternate.The spacing of the fins in general is such that it promotes convectionof air and namely to promote convection of heated air out of vents inthe vicinity of the fins. The fins will extract heat from the heatsinksby thermal conduction away from the central portions of the set top box.On one side of the set top box, the fins 8B and 8T can be alternating.In some cases, alternating may not be necessary. Also, the minor topheatsink 1A can have end fins 8TT. It should be mentioned that it ispreferred to have the fins being vertically orientated and parallel toeach other.

FIG. 7 is a bottom front perspective view without the bottom or baseframe 2 of the set top box. This view shows a possible pattern for thebottom heatsink 3. Here, a peripheral planar portion of the bottomheatsink surrounds the smart card/smart card assembly 5 as shown whichcan include a smart card 5A and a smart card reader 5B that can beattached to the PCB 4. The function of the bottom heatsink is to furtherextract heat from the circuit board by transferring heat to the bottomof the set top box 10 to further permit heat to more evenly spread fromthe central portion of the set top box and dissipate out of the set topbox and away from the set top box.

FIG. 8 is a solid bottom plan view without the bottom or base frame 2 ofthe set top box. To assist in having the bottom heatsink further extractheat from the circuit board and/or heat generating components thereonare screw assembly contacts 13, which are located in the bottomheatsink. The screw assembly contacts 13 facilitate the connectionbetween the top heatsink, PCB, and bottom heatsink by screw, bolt or thelike. These screw assembly contacts 13 can be spread around theperiphery to enhance the migration of heat from the center. Throughthese screw assembly contacts, the top heatsink, PCB, and bottomheatsink can connect mechanically and thermally to the base 2. Pleasenote that all or any thermal contact points can employ thermal pads 19.The set top box can also have additional throughholes 14 through any ofthe interior components to provide opportunities to mechanical support(through screw, bolts, rivets, clips, or the like) for any of theinterior component to other interior components or the base 2.

FIG. 9 is a front perspective view of the set top box or the like withthe top 29, front 17, sides 16 assembled. In this view, elongated vents15 are shown which can be oriented horizontally at the edges of the top29, on sides 16, and at the edges of the bottom 2 of the set top box.The concept is to have the vents be in the vicinity of the fins to beabove the fins, on the sides of the fins, and under the fins. The planesof the fins can be perpendicular to the elongated vents (which areslots). The view further shows that a side 16 can include a smartcardbay 18 which receive and hold a smart card.

FIG. 10 is a bottom plan view of the set top box showing that the settop box can further include additional vent slots 17 which can beparallel to the each other and perpendicular to the vents 15. Theadditional vent slots 17 are positioned between the vents 15 andpositioned under the printed circuit board.

Some of the key features in the device can include having a top sideheatspreader 1 attached to the main integrated circuit (IC) on the PCBin which the main IC can be the major heat generator; the top sideheatspreader 1 attached to an area of the PCB where the smart cardassembly contacts are positioned such that the contacts can be in athermally sensitive area; and a bottom side heatspreader 3 being onlyattached to the PCB at the outer sides.

In some of the embodiments, the top side heatspreader 1 has more roomabove the PCB because the connectors are on the top side of the PCB.Hence, a maximum number or a necessary number of embosses can beemployed to attach the top heatspreader to the PCB to draw as much heatas possible into the heatspreader.

In some embodiments, the top side smart card heatspreader 1 a isminimally attached to the PCB with only one screw emboss and one embossjoined to the PCB via a thermal pad. Generally, the bottom sideheatspreader does not have much room under the PCB so the center of thisheatspreader does not have any embosses to the PCB in some embodiments.

The bottom heatspreader can also function as a radiation shield for thebottom of the enclosure. The radiation is absorbed by the heatspreaderand heat is conducted throughout to prevent hot spots on the bottom ofthe enclosure. There can be some embosses on the bottom heatspreader 3to the PCB on the sides or periphery of the PCB, where the heat is lessconcentrated.

An important feature of the embodiments is that all the heatspreaderscan have a series of vertical fins formed on the sides that overhang thePCB. Since many prefer or require no vent openings directly above thePCB, these fins are outboard of the PCB and the associated vents 15 arealso outboard of the PCB horizontal profile. The vents 15 can be in thebottom, top and sides of the enclosure in those outboard areas. Thisallows the intake of cooling air from the bottom and allows the exhaustof heated air through the top due to natural convection.

Thermal finite element analysis (FEA) simulations have been performed onset top boxes according to the disclosed embodiments. The simulationshave shown that the heat management system according to the invention iseffective at dissipating heat. In particular, set top boxes generatingup to 18 Watts of power have been able to safely allow the device toreach and stay at a favorable steady state condition using the disclosedheat management system. In particular, the heatsinks/heatspreaders wereeffective and helped to achieve and create favorable steady stateconditions in which (1) the hot spot on the circuit board was under thethermal pad and was about 71.0 C, (2) the hot spot of top heatsink wasat its center and was about 66.1 C with the center of the top heatsinkcontacting the circuit board and/or the thermal pad thereon, and (3) thefins of the top heatsink reached and stayed at temperatures of around 59C. At these steady state temperature values, heat was effectivelyremoved via the fins 8 through the vents 15.

The invention can include the feature of the fins attached to the topheatsink and bottom heatsink alternating along the entire lengths of theshorts sides of the set top box. Such a configuration can be employed onone side or both sides.

Although the illustrative embodiments have been described herein withreference to the accompanying drawings, it is to be understood that thepresent principles are not limited to those precise embodiments, andthat various changes and modifications may be effected therein by one ofordinary skill in the pertinent art without departing from the scope orspirit of the present principles. All such changes and modifications areintended to be included within the scope of the present principles asset forth in the appended claims.

1. An electronic device comprising: a printed circuit board; a firstheatspreader having a first plate portion and first fins along two sidesof the first plate portion, the first plate portion above the printedcircuit board; and a second heatspreader having a second plate portionand second fins along two sides of the second plate portion, the secondplate portion below the printed circuit board; wherein the firstheatspreader has a cutout portion in a plane of the first plate portion;a third heatspreader, the third heatspreader having a third plateportion, the third plate portion positioned in the cutout portion in thefirst plate portion.
 2. The electronic device of claim 1, wherein thethird plate portion has additional fins along one side of the thirdplate portion.
 3. The electronic device of claim 1, further comprisingexterior sides and at least one of the exterior sides has at least onevent positioned adjacent to at least one of the fins.
 4. The electronicdevice of claim 1, wherein the first fins are oriented vertically andare parallel to each other.
 5. The electronic device of claim 1, whereinthe second fins are oriented vertically and are parallel to each other.6. The electronic device of claim 1, wherein the first and second finsare oriented vertically and are parallel to each other.
 7. Theelectronic device of claim 1, wherein a plurality of the first andsecond fins alternate with one another along both sides of the first andsecond plate portions.
 8. The electronic device of claim 7, furthercomprising a plurality of the exterior sides having at least one ventpositioned adjacent to the fins, wherein the vents are orientedperpendicularly to the fins.
 9. The electronic device of claim 7,further comprising a plurality of the exterior vertical sides, a top andbottom, wherein two of the exterior vertical sides and edge portions ofthe top and bottom having a plurality of vents positioned adjacent tothe fins, wherein the vents are perpendicular to the fins.
 10. Theelectronic device of claim 7, further comprising: a bottom portion ofthe electronic device having first vents positioned adjacent to the finsat opposite edges of the bottom portion; and second vents between thefirst vents.
 11. The electronic device of claim 10, wherein the firstvents are elongated and are perpendicular to the fins and the secondvents are elongated and are parallel to the fins.
 12. The electronicdevice of claim 11, wherein the first vents positioned adjacent to thefins at opposite edges of the bottom and second vents between the firstvents.